Operating Instructions

Arc welding robot manipulators

Model No. YA-1TAR81 series

Model number
YA-1TAR81*00
(TA-1600WG Ⅲ )
YA-1TAR81*01
(TA-1800WG Ⅲ )
YA-1TAR81*02
(TA-1900WG Ⅲ )

YA-1TAR81*H0
(TA-1600WGH Ⅲ )
YA-1TAR81*H1
(TA-1800WGH Ⅲ )
YA-1TAR81*H2
(TA-1900WGH Ⅲ )

TAWERS (WG Ⅲ )
- The Arc Welding Robot System -

Before operating this product, please read the instructions carefully and save this manual for future use.
• First of all, please read “Safety precautions” or “Safety manual.”

OM1010105E04

1108
 ♦Introduction
This document explains installation, safety and periodical
inspection of Panasonic welding robots.(TA-1600WG Ⅲ /
1800WG Ⅲ /1900WG Ⅲ / TA-1600WGH Ⅲ /1800WGH Ⅲ
/1900WGH Ⅲ models)

♦About safety
Read "SAFETY MANUAL" and "Operating instructions" of
the applied Robot Controller prior to starting installation
and operation of the robot.

Only qualified service personnel may install or service the

robot system.

Ensure compliance with all local and national safety and

electrical codes for the installation and operation of the
robot system.

♦Warning symbols for safe usage

Each symbol describes things to be observed to prevent you and other personnel from hazardous conditions or damage to property.

• The followings explains harzardous conditions or damages that are classi- • The following symbols indicates things
fied into the following three levels. to be observed.

DANGER A hazardous situations including death

or serious personal injury is imminent.
Things that MUST NOT
be performed.

The potential for a hazardous accident

WARNING
Things that MUST be
including death or serious personal
performed.
injury is high.
The potential for hazardous accident

CAUTION including light personal injury and/or the

potential for property damage are high.
Things attention must
be paid to.

♦Disclaimer
Panasonic Welding Systems Co., Ltd., (hereinafter called “PWS”)
and its affiliates (including any subcontractor, sales company or
agent) shall not assume or undertake any responsibility or liability
of the followings:
• Any problem arising out of, or directly or indirectly attributable to,
the failure of user to carry out those normal maintenance, nor-
mal adjustment and periodical check of this Product.
• Any problem arising out of any Force Majeure, including but not
limited to, act of God.
• Any malfunction or defect of this Product that is directly or indi-
rectly the result of any malfunction or defect of one or more
related parts or products that are not supplied by PWS. Or any
problem arising out of, or directly or indirectly attributable to, the
combination of this Product with any other product, equipment,
devices or software that is not supplied by PWS.
• Any problem arising out of, or directly or indirectly attributable to,
user’s failure to strictly carry out or follow all of the conditions
and instructions contained in this instruction manual, or user’s
misusage, mishandle, operational miss or abnormal operation.
• Any problem arising out of this Product or the use of it, the
cause of which is other than the foregoing but is also not attrib-
utable to PWS.
• Any claim of a third party that this Product infringes the intellec-
tual property rights of such third party that are directly or indi-
rectly caused by User’s use of this Product and relate to the
method of production.
ANY LOST PROFITS OR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR
ARISING FROM ANY MALFUNCTION, DEFECT OR OTHER
PROBLEM OF THIS PRODUCT.

• The description of this manual is based on the contents as of August, 2011.

• The contents of this manual are subject to change without further notice.
• English version is the original instructions.

2 OM1010105E04
♦About model No. “YA-1TAR81***”
Of the model numbers, “***” consists of one alphabetical character followed by two alphanumeric characters.

(1) One alphabetical character (T, Y, E, R or U)

One
alphabetical Basic design policy
character

T: Standard model for Japan

Y: Standard model for overseas
The model T, Y, R, U cannot be exported to EU and EEA countries without specification changes because these
models do not meet the EC Directives. The EC Directives are manufacturing prescriptions intended to guaran-
T or Y tee a standard level of quality, reliability and safety for all industrial goods produced and marketed across the
EU and EEA.
Be sure to consult us before attempting to relocate or resell these models to or in EU and EEA countries.
Note
In the US, Canada, and EU and EEA countries, use the following models made for these countries.

E: Standard model for EU member states

The model E is designed in accordance with the following European directives and harmonized standards:
EU directives : 2006/42/EC, 2006/95/EC and 2004/108/EC.
EN standards : EN ISO 10218-1:2008, EN 60204-1:2006, EN 60974-1:2005, EN 60974-5:2008,
EN 61000-6-4:2007, EN 61000-6-2:2005 and EN 60974-10:2007.
The robot system must be made in accordance with the manufacturer’s specification described in this manual
E and instruction manual.
Remodeling and/or modifying this product not in accordance with the manufacturer’s specification will invalidate
this declaration.
Authorised Representatives:
Panasonic Testing Centre
Panasonic Marketing Europe GmbH
Winsbergring 15, 22525 Hamburg, Germany

R: Standard model for the US

The model T, Y, R, U cannot be exported to EU and EEA countries without specification changes because these
models do not meet the EC Directives. The EC Directives are manufacturing prescriptions intended to guaran-
tee a standard level of quality, reliability and safety for all industrial goods produced and marketed across the
R
EU and EEA.
Be sure to consult us before attempting to relocate or resell these models to or in EU and EEA countries.
The installation shall be made by qualified installation personnel and should conform to all national and local
codes.

The model U is designed in accordance with the following safety regulations and standards used in the US and Can-
ada:
UL1740:1998
ANSI/RIA R15.06-1999
NFPA79-1997
CAN/CSA Z434-1994
The model T, Y, R, U cannot be exported to EU and EEA countries without specification changes because these
U models do not meet the EC Directives. The EC Directives are manufacturing prescriptions intended to guaran-
tee a standard level of quality, reliability and safety for all industrial goods produced and marketed across the
EU and EEA.
Be sure to consult us before attempting to relocate or resell these models to or in EU and EEA countries.
The installation shall be made by qualified installation personnel and should conform to all national and local
codes.
Notice: Exporting the machine to Canada (U)
Exporting this product to Quebec, Canada requires all the name plates and French operating instructions.

OM1010105E04 3
 (2) Two alphanumeric characters
Two alphanu-
Type
meric characters
00 YA-1TAR81(TA-1600WG Ⅲ ) Medium arm
Floor For welding
01 YA-1TAR81(TA-1800WG Ⅲ ) Long arm
installation (350 A power source)
02 YA-1TAR81(TA-1900WG Ⅲ ) Long arm (Payload: 6 kg)
H0 YA-1TAR81（TA-1600WGH Ⅲ）Medium arm
For welding
Floor
H1 YA-1TAR81（TA-1800WGH Ⅲ）Long arm (450 A power source with
installation
high power wire feeder)
H2 YA-1TAR81（TA-1900WGH Ⅲ）Long arm (Payload: 6 kg)

• Example:
Model “YA-1TAR81U00” is a floor installation type robot manipulator for welding operation with medium arm (TA-
1600WG Ⅲ ) for US and Canada.
Note
As for the design group T and Y of the WG models, if the second alphanumeric character of the robot model
number is “A”, i.e. “TA*” or “YA*”, the controller can switch the input voltage from 200 V to 220 V.

4 OM1010105E04
 ♦Table of Contents
1. Accessories ............................................. 6
2. Transportation ...................................7
3. Installation...........................................8
3.1 Choosing an installation site ...................8
3.2 Strength requirement of the foundation .9
3.3 Floor type.................................................10
3.4 Ceiling type..............................................11
3.5 Safety fence.............................................12
3.6 Adjustment ..............................................14
3.7 Mounting holes for zone monitoring jig15
4. Connection........................................16
4.1 Connecting the manipulator to the control-
ler ..............................................................16
4.2 Grounding................................................16
4.3 Connecting to the wire feeder ...............17
4.3.1 Connecting welding torch cable ............... 17
4.3.2 Fixing welding torch cable ........................ 17
4.3.3 Connecting a flexible conduit ................... 18
4.3.4 Connecting a welding power cable........... 18
4.3.5 Fixing the welding power cable at the rear side
(TA-***WG type only)................................... 18
4.3.6 Fixing welding power cable of the ceiling type
robot............................................................. 19
4.3.7 Installing feed rollers and a welding wire.. 19
4.3.8 Wire feeding instruction ............................ 19
5. Technical data...................................20
5.1 Specifications..........................................20
5.1.1 Medium arm type (TA-1600WG Ⅲ / TA-
1600WGH Ⅲ ) ............................................. 20
5.1.2 Long arm type (TA-1800WG Ⅲ/ TA-1800WGH
Ⅲ ) ............................................................... 22
5.1.3 Long arm and 6 kg payload type (TA-1900WG
Ⅲ / TA-1900WGH Ⅲ ) ................................. 24
5.1.4 .Wire feed unit........................25
5.2 Outer dimensions ...................................26
5.2.1 Robots with standard feeder .................... 26
5.2.2 450 A welding power source with high power
feeder........................................................... 28
5.3 Maximum payload...................................30
5.3.1 Limitation of the load on the wrist axis ..... 30
5.3.2 Mounting system accessories on the front arm
axis .............................................................. 32
5.3.3 Limitation of the load on the front arm axis33
5.4 Collision detection..................................35
5.5 Mounting plane of protective fixture .....35
OM1010105E04
5.6 Setting welding torch ............................. 36
5.7 Tool center point .................................... 36
5.8 Tool offset .............................................. 37
5.9 Set-up ...................................................... 37
5.10 Work envelope ...................................... 38
5.10.1 Standard arm type (TA-1600)................. 38
5.10.2 Long arm type (TA-1800) ...................... 40
5.10.3 Long arm and 6 kg payload type (TA-1900)
42
6. Electrical equipment and wiring parts
44
6.1 Location of the limit switches ............... 44
6.2 Adjusting the limit switches .................. 45
6.2.1 Adjusting the limit switch of RT-axis ......... 45
6.2.2 Adjusting the limit switches of UA and FA axes
46
6.3 Connecting cables and hoses ............... 47
6.4 Connecting power cable ........................ 48
6.5 Internal wiring ......................................... 49
6.6 Manual brake release switch ................. 52
6.7 Servo-ON indicator lamp ....................... 52
7. Maintenance and inspection........... 53
7.1 Daily check.............................................. 53
7.2 Periodical inspection ............................. 54
7.3 Backup battery replacement ................. 55
7.4 Setting adjustment pins ......................... 56
7.5 Checking bolts tightening torque for wire
feeder........................................................ 57
7.6 Maintenance of wire feeder ................... 58
7.6.1 Maintenance and periodical check ........... 58
7.6.2 Change of feed rollers, stainless tube and cen-
ter tube......................................................... 59
8. Repair parts lists.............................. 60
8.1 Robot manipulators................................ 60
8.2 Wire feeder (Standard) ........................... 63
8.2.1 Motor unit.................................................. 64
8.3 Wire feeder (Standard) ........................... 65
8.3.1 Motor unit.................................................. 66
8.4 Wire feeder (High power / For 450 A weld-
ing power source).................................... 67
8.4.1 Motor unit ................................................... 68
9. Appendix .......................................... 69
9.1 Location of the labels............................. 69
9.2 Details of the labels ................................ 70
5
 Accessories

1.Accessories
Before using this product, be sure to check that the following accessories are included.

Part number
Description Part number to order Quantity

Hexagon bolt XVH16C75-75 XVH16C75-75 4

Spring washer XWB16BFJ XWB16BFJ 4
Washer XWF16FJ XWF16FJ 4
Nut XNH16GFJ XNH16G 4
RT stopper ABQ41033 ABQ41033 1
Hexagon socket head bolt XVE12C20FP XVE12C20FP 1
Rubber cover AWK41018 AWK41018 1

6 OM1010105E04
 Transportation

2.Transportation
♦Transportation method
Only qualified personnel should operate a crane or a forklift to trans-
CAUTION port the manipulator.

Avoid applying any force to the arm or the motor part of the robot when transporting.

Use a crane to transport the manipulator for installation or

re-installation. Hang the manipulator with wires through
the two eyebolts as illustrated in the following figure.

α=50°

Note
If you lose or break the eye bolt, purchase Panasonic
genuine one for safe transportation.

OM1010105E04 7
 Installation

3.Installation

Installation work involves risk and is important for safe work environment.
CAUTION Contact our qualified personnel for the installation.

3.1 Choosing an installation site

(1) What you need to prepare
(a) Mounting base for the robot
(b) Foundation for the robot installation, concrete
and coating, piping and piping pit
(c) Primary power wiring
(d) Grounding
(e) (Provide 100 Ω or less grounding exclusively)
(f) Piping for shield gas outside of the system
(g) Interface and connection between jig and
robot controller
(2) Installation site
(a) A site where ambient temperatures are as
follows and away from direct sunshine.
•In operation: 0 ℃ to 45 ℃
(3) International protection code (IP rating)
•In transit or in storage: -25 ℃ to 60 ℃
(b) Be sure to locate the controller close to but
outside of the work envelope of a manipulator.
(c) A site relatively free of humidity, dust, or
lampblack.
(d) A site free of combustible or corrosive gas.
(e) A site where no obstructions present within
the work envelope of the manipulator.
(f) A site easily accessible in case of inspection
or disassembly.
(g) A site relatively free of shock and vibration.
(h) A site where no electrical noise source exists.
*If a significant noise source such as plasma
or high frequency exists at or around the
installation site, please consult us in advance.
(i) Install indoors
(j) Avoid installing at sites where water or rain is
around.
(k) 1 000 m ASL or less
•Manipulators: Equal to IP40
(Only the wrist of 1600 type is equal to IP54.)
•Wire feeder : Equal to IP20

8 OM1010105E04
 Installation

3.2 Strength requirement of the foundation

Install the manipulator to the foundation that can
resist weight of the jig and the manipulator and the
following maximum reaction force of the moving
manipulator.
Maximum reaction force of the manipulator
Note
Do not install the manipulator to a poor strength foun-
dation.
If the foundation is not strong enough to support the
manipulator, make sure to reinforce it.

TA series Models TA-1600 TA-1800 TA-1900

Vertical moment (N•m)
Maximum reaction force 5 100 6 100 5 800
(UA axis rotation direction)
in operation
(Floor installation) Horizontal moment (N•m)
3 400 4 000 3 800
(RT axis rotation direction)

OM1010105E04 9
 Installation

3.3 Floor type

Install the robot manipulator firmly and securely.
(4) (6)
About foundation:
• If the concrete part of the floor is 150 mm or more (5)
thick, the floor can be used as the foundation for
the installation.
(1) (3)
• If the concrete part of the floor is less than 150 mm
thick, dig out the installation site for foundation. (2)
• If the floor is not flat, apply shim plates of 100 mm- (2): Boulder
(1): Concrete
square or more to four corners of the robot base. (3): 150mm or more (4): 450mm or more
(5): 300mm-square (6): 4-M16,depth 60mm or more

How to transport the manipulator to the installation site:

(1) Hook the wires to the eyebolts on UA body.
(2) Lift and transport the robot manipulator to the
installation site.
Note
Prevent the wires from touching any part of the
manipulator.

How to install the manipulator:

300-square
(1) To fix the manipulator, use the four holes at the
corners. 115
4- φ18
(2) Use the holes (2-φ12H7) for positioning if nec-
essary.
160
Note
Use the provided hexagon bolts (4-M16x75) to install
the base. (Tightening torque: 106 N•m or more) 160

115 2- φ12H7

Unit: (mm)

Hexagon bolt
4-M16 x 75 Spring washer

Washer

10 OM1010105E04
 Installation

3.4 Ceiling type

CAUTION Have a contractor install the ceiling type robot for safety.

Install the robot manipulator firmly and securely.

About foundation: (3)

(5)
• Use the steel sheet of 25 mm thick or more for (4)
mounting surface.
• If the mounting surface is not flat, apply shim plates (2)
of 100 mm-square or more to four corners of the
robot base.

How to transport the manipulator to the installation site:

(1)
(1) Hook the wires to the eyebolts on UA body.
(2) Lift and transport the robot manipulator to the
installation site. 1: Safety fitting 2: 25 mm or more
3: 450 mm-square or more 4: 300 mm-square
Note
5: 4-M16 ( 60-mm depth or more)
Prevent the wires from touching any part of the
manipulator.

How to install the manipulator:

300-square
(1) To fix the manipulator, use the four holes at the
corners. 115
4- φ18
(2) Use the holes (2-f12H7) for positioning if neces-
sary.
(3) Make sure to set the safety fitting to prevent fall-
160
ing.
Note
• Use the provided hexagon bolts (4-M16x75) to 160
install the base. (Tightening torque: 106 N•m or
more)
• Take away an unused manipulator to prevent fall- 115 2- φ12H7
ing. Do not leave it hanged.
(Unit: mm)

Washer

4-M16 x 75 Spring washer

Hexagon bolt

OM1010105E04 11
 Installation

3.5 Safety fence

Install the robot where the end effector attached to
the robot arm does not touch the side wall(s), safety
fence, or controller when it extended completely.
The safety fence must meet the following require-
ments:
(1) The safety fence must be strong enough to
resist vibration, impact, and other conditions
caused by operation.
(2) The safety fence must be strong enough to
resist maximum possible impact of the clash
within the maximum payload weight of the robot.
(3) The safety fence must be easily adjustable and
removable, and difficult to get over.
(4) The safety fence must have no dangerous part
such as sharp edges or projections.
(5) The safety fence must be secured to the ground.
(6) The safety fence with a door must be provided
with interlocking system between the door and
the robot. The interlocking system must take the
following into consideration:
(a) The size, capacity, and speed of the robot.
(b) Potential risks during the installation, pro-
gramming, operation, trouble shooting and
maintenance of the robot system.
(c) Close approach to the robot when the power
is available at the robot actuators.
(d) The robot cannot control its emergency stop
position precisely because it depends on the
energy of the robot motion.
Note
The robot system must be designed, constructed,
and installed so that the failure of any single compo-
nent, whether electrical, electronic, mechanical,
pneumatic, or hydraulic, does not affect the safety
functions. Even if some of the safety functions are
affected, the robot system must be kept in a safe
condition.
Safety functions must include, but are not limited to,
the following:
• Limitation of range of motion
• Emergency or safety stop
• Reduced speed operation
• Safeguard interlocking

• Interlocked door

500 mm or more
Safety fence

End effector
Manipulator

500 mm or more 500 mm or more

Max. work envelope of the

manipulator including
attached end effector

500 mm or more

Interlocked door Robot controller

(7) When installation of safety fence is impossible
and an operator is within the working work enve-
lope of the robot, stop the robot system by
installing area sensor or high-sensitive mat at
every place within reach of the robot system.
The system integrator must meet the require-
ments of standard EN ISO 13855. Failure to
install the safety fence can create additional
risks.

12 OM1010105E04
 Installation

• Light curtain (or pressure sensitive mats)

Robot controller Interlocked door

Safety fence
500 mm or more

Manipulator

500 mm or more 500 mm or more

Light curtain

The minimum distance from the danger zone can be calculated by the following formula.
S=(K x T) + C
where:
S is the minimum distance in millimeters, from the danger zone to the detection point, line, plane or zone;
K is a parameter in millimeters per second, derived from data on approach speeds of the body or parts of the body;
T is the overall system stopping performance in seconds (see also stopping time in section “4.1 Specifications” of this document);
C is an additional distance in millimeters, based on intrusion towards the danger zone prior to actuation of the protective
equipment.
For more details, see standard EN ISO 13855.

• Safety fence is not a rectangle, but an asymmetric shape

500 mm or more
Safety fence
Manipulator

500 mm or more

500 mm or more 500 mm or more

500 mm or more

500 mm or more

Interlocked door
Robot controller

OM1010105E04 13
 Installation

3.6 Adjustment
To ensure a safe area, limit the working range of the
RT axis. Adjust the position of the stopper bolt for
appropriate limitation, and then adjust the parame-
ters of the soft-limit accordingly. (Refer to the section
“Soft limit settings” of the operating instructions
[Operation].) The stopper bolt is pre-positioned for
the working range of ±170 degrees as the figure
below.

Mechanical stopper
Stopper bolt
(UA body side)
(M12x20)

RT stopper
(RT base side)

RT axis is provided with 10 holes equally spaced (i.e.

Example: Working range of RT axis is limited to ±80-deg
30 degrees intervals) for the stopper bolt. (See the fig-
ure on the right.) (RT axis part: top view)
To adjust working range, change positions of the pre-
installed stopper bolt (M12x20) and RT stopper, and
install the provided stopper bolt(M12x20) and RT
stopper.

Also see section "6.2 Adjusting the limit switches" for

details.

Front

Stopper bolt: Factory preset position

(RT axis working range: ±170)

(Unit:mm)

14 OM1010105E04
 Installation

3.7 Mounting holes for zone monitoring jig

4-M6 through-holes

OM1010105E04 15
 Connection

4.Connection
4.1 Connecting the manipulator to the controller
The production number of the manipulator and the
controller must be the same. Check the production
numbers first. Push down the fixing lever in the direction
of the arrow to fix the connector.
(1) Connect the cable connector of the controller to
the connector of the manipulator. Push in the connector
(2) Push in the cable connector until the gap until the gap becomes
Cable connector 1 mm or less.
between the connectors becomes 1 mm or less. (Controller side)
(3) Push down the fixing lever in the direction of the
arrow to fix the connection.
(4) Check that the connector is fixed securely.
Note
Connector
Push in the connector completely. If the gap between (Manipulator side)
the connector is more than 1 mm and the fixing lever
is pushed down forcibly, the joint of the connector
could be shifted, which can damage the pins. Note
The allowable bending radius of connecting cable is
175 mm or more.

4.2 Grounding
Provide grounding to the protective earth terminal (PE) of the robot con-
CAUTION troller exclusively. Check the grounding before operation.

Two 14 mm2 (AWG6) Green/yellow wires are provided for

Grounding Additional protective
grounding as accessory. Countries
resistance conductor

Note Japan 100 ohm or less 14 mm2 or more.

For sizes of the protective conductors for other devices, fol- EU 100 ohm or less 14 mm2 or more.
low the instructions of the each device.
USA 0.1 ohm or less AWG6 or more
The others Conform to all national and local codes

Factory ground cable

Provide required grounding exclusively

200 VAC 200 VAC (Separate grounding work near the controller.)

Protective grounding conductor

For safety, connect ground

14 mm2 or more* cable without fail.

(2 cables are provided.)

Other unit Controller Manipulator * Be sure the size of the protective

ground conductor conform
to the local codes where the
Cable the product is installed.
Teach
pendant PE terminal FE terminal

16 OM1010105E04
 Connection

4.3 Connecting to the wire feeder

4.3.1 Connecting welding torch cable
(1) Connect a welding torch with the wire feeder so
that the gas inlet and the user cable are on the Signal cable
upper side, and fix it with a fastening bolt. Gas inlet Gas hose
(2) Connect the signal cable of the welding torch to User cable connector
the user cable connector of the wire feeder.
(3) Connect the gas inlet of the welding torch to the Fastening bolt
wire feeder with the gas hose ( AWG41018).

Gas outlet

4.3.2 Fixing welding torch cable

* For details, refer to the operating instructions of
“Fixing welding torch cable unit”; OM0504036JE. Saddle
Bolt 2-M4 x 12 Use rubber sheet.

(1) Mount the cable fixing hanger on the RW body of

the manipulator and fix it.
< Note > Cable fixing hanger

For models; TA-****WGH and TA-****WGD,

mount the cable fixing hanger on the fixing board
of the wire feeder. Bolt 4-M5 x 12(SW,W)

(2) Wrap the rubber sheet firmly around the cable.

<For TA-****WGH, TA-****WGD>
Fix the cable to the cable fixing hanger with the
saddle. Cable fixing hanger

Note
Wrap the rubber sheet completely to avoid friction Bolt M5x20, SW, W
between the cable and the cable fixing plate. Plate screw
(from backside)

OM1010105E04 17
 Connection

4.3.3 Connecting a flexible conduit

(1) It applies coupling type flexible conduit for robot
welding system. Wire feeder
(2) Attach the socket of the flexible conduit to the Flexible conduit metal
flexible conduit metal. If the flexible conduit Flexible conduit
metal rotates together with the socket, use the
fixation screw (M5x10).

Note
Fixation screw
About flexible conduit: “LOCK/UNLOCK”: (M5x10)
Lock the flexible conduit to prevent the flexible con-
duit from falling off during robot operation by turning
the flexible conduit socket. Flexible conduit
UNLOCK it to attach or remove the flexible conduit. socket

LOCK

UNLOCK

4.3.4 Connecting a welding power cable

Connect a welding power cable to the CC fitting of
Bolt (*)
the wire feeder.
Wire feeder

Note
(*)
: Tighten the bolt at the tightening torque of 23 N•m
±0.2 N•m. Loose bolt may cause heat generation
or fire.

Welding power cable C.C. fitting

4.3.5 Fixing the welding power cable at the rear side (TA-***WG type only)

Welding power cable

This fixing method is not available to the models;
TA-****WGH and TA-****WGD.
Rubber sheet

When the welding power cable is fixed at the rear

side of the wire feeder, purchase the rear fixing unit
W; AFU01257, separately.
Note
Fix the rear plate with the bolts (4-M5x12) and then
fix the welding power cable with the saddle, rubber Saddle
sheet and the bolts (2-M4x10). Make sure that the
2-M4X10
welding power cable does not interfere with the
feeder cable.
Rear plate Feeder cable
4-M5X12

18 OM1010105E04
 Connection
4.3.6 Fixing welding power cable of the ceiling type robot
The welding power cable of the ceiling type robot can
only be fixed at the rear side.
Note
Refer to the operating instructions of the torch cable
fixing unit for how to fix the cable.

4.3.7 Installing feed rollers and a welding wire

(1) Install feed rollers on the wire feeder.
Pressure nut Pressure arms Pressure nut
< Note >
Each feed roller has two grooves for each wire
Ａ Ａ
size. Install the feed rollers so that chosen wire Ａ
size is displayed on outside face of the feed roll-
ers.

(2) Install a welding wire.

(a) Lift up the pressure arms and insert a wire CC fitting
into the CC fitting metal by 2 cm to 8 cm.
Feed rollers Stainless tube
(b) Return the pressure arms and lock them with
the pressure nuts.

(3) Adjust wire pressure with the pressure nuts. The

diameter of each wire is calibrated on the shafts
of the pressure nuts. Match the bottom face of
the pressure nut with the calibrations.

Pressure nut
Calibrations of wire size

4.3.8 Wire feeding instruction

(1) Select the TEACH mode.

(2) On the user function menu bar, turn on the

(Wire/gas check) key for wire/inching gas check.
(3) Turn on the servo power of the robot

(4) Press the wire (Wire feed forward) key of

the function key.
Hold down the key until the wire comes out 1 cm
to 2 cm from the tip. Then release the key.
Note
Refer to the operating instructions of the teach pen-
dant (section“5.10 Teach weld section”) for how to
change the wire feed speed.

OM1010105E04 19
 Technical data

5.Technical data
5.1 Specifications
5.1.1 Medium arm type (TA-1600WG Ⅲ / TA-1600WGH Ⅲ )
1)With standard wire feeder
Robot model No. Manipulator code No. Installation Remarks
YA-1TAR81*00 YA-1QMR82*00 Floor
(*) is T, Y, E, R or U depending on the type
YA-1TAR81*H0 YA-1QMR82*H0 Floor

Items Specifications
Structure Independent articulated
Degree of freedom 6
Rotation (RT)
±170°
(Referenced from front)
Upper arm (UA)
Robot movement range

(Referenced from vertical) +165° to -90° (+165° to -90°) *1

Arm
(Referenced
+270° to -205° (+205° to -270°) *1
Front arm from horizontal)
(FA) (Referenced
from upper arm) +210° to -80° (+80° to -210°) *1

Rotating (RW) ±270° (+450° to -90°) *1

Wrist Bending (BW)
+95° to -160°
(Referenced from front arm)
Twisting (TW) ±400°
Point P*2 5.61 m2 x 340°
Section area of arm motion Point
4.84 m2 x 340°
O*2
Robot working area

Lengthwise arm motion (Dis- Point P*2 +1 598 mm to -1 288 mm

tance from the center of RT- Point
axis to the center of BW-axis.) +1 538 mm to -1 228 mm
O*2
Vertical arm motion (Distance Point P*2 +1 863 mm to -1 001 mm (+1 001 mm to -1 863 mm) *1
from the lower surface of the
robot to the center of BW- Point
+1 803 mm to -941 mm (+941 mm to -1 803 mm) *1
axis.) O*2
Rotation (RT) 2.97 rad/s (170° /s)
Arm Upper arm (UA) 2.97 rad/s (170° /s)
Max. speed
Momentary

Front arm (FA) 3.05 rad/s (175° /s)

Rotating (RW) 6.28 rad/s (360° /s)
Wrist Bending (BW) 6.11 rad/s (350° /s)
Twisting (TW) 9.42 rad/s (540° /s)
Maximum payload 8 kg

20 OM1010105E04
 Technical data

Items Specifications
Rotating (RW) 23.5 N•m (2.40 kgf•m)
Allowable load

Moment Bending (BW) 23.5 N•m (2.40 kgf•m)

on wrist

Twisting (TW) 9.8 N•m (1.00 kgf•m)

Rotating (RW) 0.720 kg•m2 (0.0735 kgf•m•s2)
Inertia Bending (BW) 0.720 kg•m2 (0.0735 kgf•m•s2)
Twisting (TW) 0.125 kg•m2 (0.0128 kgf•m•s2)
Positioning repetition precision ±0.1 mm or less
Position detector Multi rotational resolver with backup data
Rotation (RT) 1 200 W (AC servo motor)
Arm Upper arm (UA) 1 600 W (AC servo motor)
Drive power

Front arm (FA) 750 W (AC servo motor)

Rotating (RW) 400 W (AC servo motor)
Wrist Bending (BW) 200 W (AC servo motor)
Twisting (TW) 100 W (AC servo motor)
Brake All axes are provided with brakes.
Brake releasing Standard or optional depends on the model.
Soft limit Provided
Operation limit protec- RT: Standard equipment
Hard limit
tion UA, FA: Standard or optional depends on the model.
Mechanical stopper Main 3 axes
Stop at full speed Stopping time Max. 0.35 s *3
(main 3 axes) Stopping angle Max. 15 degrees*3
Grounding Required
Sound power level 75 dB (A)
RT: Munsell color system N3.5 or the equivalent
Body color
The others: Munsell color system N7.5 or the equivalent
Equal to IP40
Protection rating
(Only the wrist is equal to IP54)
Installation position Floor type / Ceiling type *4
Outer dimensions See outer drawings
0 °C to 45°C, 20 % RH to 90% RH
Ambient temperature, humidity (50 % or less at 40 °C, 90 % or less at 20 °C)
(No dew condensation)
Shipping and storage temperature - 25 °C to 60 °C
Weight (Wire feeder is not included.) About 203 kg (About 447 lbs.)
* 1: Values in parentheses are for ceiling type and factory set.
* 2: For details of point O and P, see the "WORK ENVELOPE."
3
* : Values were measured in maximum load, speed, and extension conditions.
*4: Ceiling type is optional at shipment.

OM1010105E04 21
 Technical data

5.1.2 Long arm type (TA-1800WG Ⅲ / TA-1800WGH Ⅲ )

1)With standard wire feeder
Robot model No. Manipulator code No. Installation Remarks
YA-1TAR81*01 YA-1QMR82*01 Floor
(*) is T, Y, E, R or U depending on the type
YA-1TAR81*H1 YA-1QMR82*H1 Floor

Items Specifications
Structure Independent articulated
Degree of freedom 6
Rotation (RT)
±170°
(Referenced from front)
Upper arm (UA)
Robot movement range

(Referenced from vertical) +165° to -90° (+165° to -90°) *1

Arm
(Referenced
from horizontal) +270° to -205° (+205° to -270°) *1
Front arm
(FA) (Referenced
from upper arm) +210° to -80° (+80° to -210°) *1
Rotating (RW) ±270° (+450° to -90°) *1
Wrist Bending (BW)
+95° to -160°
(Referenced from front arm)
Twisting (TW) ±400°
2
Point P * 7.24 m2 x 340°
Section area of arm motion
Point O *2 6.31 m2 x 340°
Robot working area

Lengthwise arm motion (Dis- Point P *2 +1 796 mm to -1 486 mm

tance from the center of RT-
axis to the center of BW-axis.) Point O *2 +1 736 mm to -1 426 mm
Vertical arm motion (Distance Point P *2 +2 061 mm to -1 198 mm (+1 198 mm to -2 061 mm) *1
from the lower surface of the
robot to the center of BW-
Point O *2 +2 001 mm to -1 138 mm (+1 138 mm to -2 001 mm) *1
axis.)
Rotation (RT) 2.97 rad/s (170° /s)
Arm Upper arm (UA) 2.97 rad/s (170° /s)
Max. speed
Momentary

Front arm (FA) 3.05 rad/s (175° /s)

Rotating (RW) 6.28 rad/s (360° /s)
Wrist Bending (BW) 6.11 rad/s (350° /s)
Twisting (TW) 9.42 rad/s (540° /s)
Maximum payload 8 kg
Rotating (RW) 23.5 N•m (2.40 kgf•m)
Allowable load

Moment Bending (BW) 23.5 N•m (2.40 kgf•m)

on wrist

Twisting (TW) 9.8 N•m (1.00 kgf•m)

Rotating (RW) 0.720 kg•m2 (0.0735 kgf•m•s2)
Inertia Bending (BW) 0.720 kg•m2 (0.0735 kgf•m•s2)
Twisting (TW) 0.125 kg•m2 (0.0128 kgf•m•s2)
Positioning repetition precision ±0.15 mm or less
Position detector Multi rotational resolver with backup data

22 OM1010105E04
 Technical data

Items Specifications
Rotation (RT) 1200 W (AC servo motor)
Arm Upper arm (UA) 1600 W (AC servo motor)
Drive power

Front arm (FA) 750 W (AC servo motor)

Rotating (RW) 400 W (AC servo motor)
Wrist Bending (BW) 200 W (AC servo motor)
Twisting (TW) 100 W (AC servo motor)
Brake All axes are provided with brakes.
Brake releasing Standard or optional depends on the model.
Soft limit Provided
RT: Standard equipment
Operation limit protection Hard limit
UA, FA: Standard or optional depends on the model.
Mechanical stopper Main 3 axes
Stop at full speed Stopping time Max. 0.35 s *3
(main 3 axes) Stopping angle Max. 15 degrees *3
Grounding Required
Sound power level 75 dB (A)
RT: Munsell color system N3.5 or the equivalent
Body color
The others: Munsell color system N7.5 or the equivalent
Protection rating Equal to IP40
Installation position Floor type / Ceiling type *4
Outer dimensions See outer drawings
0 °C to 45°C, 20 % RH to 90% RH
Ambient temperature, humidity (50 % or less at 40 °C, 90 % or less at 20 °C)
(No dew condensation)
Shipping and storage temperature - 25 °C to 60 °C
Weight (Wire feeder is not included.) About 204 kg (About 450 lbs.)
1
* : Values in parentheses are for ceiling type and factory set.
*2: For details of point O and P, see the "WORK ENVELOPE."
*3: Values were measured in maximum load, speed, and extension conditions.
*4: Ceiling type is optional at shipment.

OM1010105E04 23
 Technical data

5.1.3 Long arm and 6 kg payload type (TA-1900WG Ⅲ / TA-1900WGH Ⅲ )

1)With standard wire feeder
Robot model No. Manipulator code No. Installation Robot model No.
YA-1TAR81*02 YA-1QMR82*02 Floor
(*) is T, Y, E, R or U depending on the type
YA-1TAR81*H2 YA-1QMR82*H2 Floor

Items Specifications
Structure Independent articulated
Degree of freedom 6
Rotation (RT)
±170°
(Referenced from front)
Upper arm (UA)
Robot movement range

(Referenced from vertical) +165° to -90° (+165° to -90°) *1

Arm
(Referenced
from horizontal) +270° to -205° (+205° to -270°) *1
Front arm
(Referenced
(FA)
from upper arm) +210° to -80° (+80° to -210°) *1
Rotating (RW) ±270° (+450° to -90°) *1
Wrist Bending (BW)
+95° to -160°
(Referenced from front arm)
Twisting (TW) ±400°
Point P *2 8.08 m2 x 340°
Section area of arm motion
Robot working area

Point O *2 7.07 m2 x 340°

Lengthwise arm motion (Dis-
Point P *2 +1 895 mm to -1 585 mm
tance from the center of RT-axis
to the center of BW-axis.) Point O *2 +1 835 mm to -1 525 mm
Vertical arm motion (Distance Point P *2 +2 160 mm to -1 297 mm (+1 297 mm to -2 160 mm) *1
from the lower surface of the
robot to the center of BW-axis.) Point O *2 +2 100 mm to -1 237 mm (+1 237mm to -2 100 mm) *1
Rotation (RT) 2.97 rad/s (170° /s)
Arm Upper arm (UA) 2.97 rad/s (170° /s)
Max. speed
Momentary

Front arm (FA) 3.05 rad/s (175° /s)

Rotating (RW) 6.28 rad/s (360° /s)
Wrist Bending (BW) 6.11 rad/s (350° /s)
Twisting (TW) 9.42 rad/s (540° /s)
Maximum payload 6 kg
Rotating (RW) 14.7 N•m (1.50 kgf•m)
Allowable load

Moment Bending (BW) 14.7 N•m (1.50 kgf•m)

on wrist

Twisting (TW) 5.9 N•m (0.60 kgf•m)

Rotating (RW) 0.375 kg•m2 (0.0383 kgf•m•s2)
Inertia Bending (BW) 0.375 kg•m2 (0.0383 kgf•m•s2)
Twisting (TW) 0.060 kg•m2 (0.0061 kgf•m•s2)
Positioning repetition precision ±0.15 mm or less
Position detector Multi rotational resolver with backup data
Rotation (RT) 1200 W (AC servo motor)
Drive power

Arm Upper arm (UA) 1600 W (AC servo motor)

Front arm (FA) 750 W (AC servo motor)
Rotating (RW) 400 W (AC servo motor)
Wrist Bending (BW) 200 W (AC servo motor)
Twisting (TW) 100 W (AC servo motor)

24 OM1010105E04
 Technical data

Items Specifications
Brake All axes are provided with brakes.
Brake releasing Standard or optional depends on the model.
Soft limit Provided
RT: Standard equipment
Operation limit protection Hard limit
UA, FA: Standard or optional depends on the model.
Mechanical stopper Main 3 axes
Stop at full speed Stopping time Max. 0.35 s *3
(main 3 axes) Stopping angle Max. 15 degrees *3
Grounding Required
Sound power level 75 dB (A)
RT: Munsell color system N3.5 or the equivalent
Body color
The others: Munsell color system N7.5 or the equivalent
Protection rating Equal to IP40
Installation position Floor type / Ceiling type *4
Outer dimensions See outer drawings
0 °C to 45°C, 20 % RH to 90% RH
Ambient temperature, humidity (50 % or less at 40 °C, 90 % or less at 20 °C)
(No dew condensation)
Shipping and storage temperature - 25 °C to 60 °C
Weight (Wire feeder is not included.) About 204 kg (About 450 lbs.)
*1: Values in parentheses are for ceiling type and factory set.
*2: For details of point O and P, see the "WORK ENVELOPE.”
*3: Values were measured in maximum load, speed, and extension conditions.
*4: Ceiling type is optional at shipment.

5.1.4 .Wire feed unit

Models APU01171 APU01138
350 A welding power source 450 A welding power source
Wire feeder type
(Standard) (High power)
Rated motor capacity 50 W AC servo motor 100 W AC servo motor
Control method Digital servo control
Wire feed control signal Digital
Applicable wires Mild steel and Stainless steel wires
Applicable wire diameter 0.9 mm, 1.2 mm 0.9 mm, 1.4 mm
Maximum feed rate 23 m/min
Protection rating Equal to IP20
Weight About 3 kg. (About 7 lbs.) About 8 kg. (About 17 lbs.)

OM1010105E04 25
 Technical data

5.2 Outer dimensions

5.2.1 Robots with standard feeder
Common to TA-1600,1800 and 1900 types except dimension of joint arm.

(Unit :mm)

Outer dimension of the manipulator (1)

26 OM1010105E04
 Technical data

depth 12

depth 12

(Unit :mm)

Outer dimension of the manipulator (2)

OM1010105E04 27
 Technical data

5.2.2 450 A welding power source with high power feeder.

Common to TA-1600,1800 and 1900 types except dimension of joint arm.

(Unit :mm)

Outer dimension of the manipulator (1)

28 OM1010105E04
 Technical data

(Unit :mm)

Outer dimension of the manipulator (2)

OM1010105E04 29
 Technical data

5.3 Maximum payload

5.3.1 Limitation of the load on the wrist axis
1)Standard arm (TA-1600) and Long arm (TA-1800)
(1) The maximum payload of each model, including (2) To use the robot for other than arc welding such
the weight of the bracket to transfer the load, is as handling, follow the restrictions in table below.
as follows:
• TA-1600, TA-1800: 8 kg (Including the bracket)
• TA-1900: 6 kg (Including the bracket)
<TA-1600, TA-1800 type>
Axes Eccentric load Load inertia
Rotation (RW) 23.5 N•m (2.4 kgf•m) or less 0.720 k g•m2 (0.0735 kgf•m•s2) or less
Bending (BW) 23.5 N•m (2.4 kgf•m) or less 0.720 kg•m2 (0.0735 kgf•m•s2) or less
Twist (TW) 9.8 N•m (1.00 kgf•m) or less 0.125 kg•m2 (0.0128 kgf•m•s2) or less

Assuming the load is concentrated at the load center, the limits of mounting dimensions are as follows.

Lb
(2)

(1)
(1): BW rotation center
L7
(2): Load center
Lt
(3): TW rotation center
L6: 60 mm
L6
L7: 155 mm

(3)

TW origin

30 OM1010105E04
 Technical data
<TA-1900 types>
Axes Eccentric load Load inertia
Rotation (RW) 14.7 N•m (1.50 kgf•m) or less 0.375 kg•m2 (0.0383 kgf•m•s2) or less
Bending (BW) 14.7 N•m (1.50 kgf•m) or less 0.375 kg•m2 (0.0383 kgf•m•s2) or less
Twist (TW) 5.9 N•m (0.60 kgf•m) or less 0.060 kg•m2 (0.0061 kgf•m•s2) or less

Assuming the load is concentrated at the load center, the limits of mounting dimensions are as follows.

Lb
(2)

(1)
(1): BW rotational center
L7
(2): Load center
Lt
(3): TW rotational center
L6: 60 mm
L6
L7: 155 mm

(3)

TW origin

OM1010105E04 31
 Technical data

5.3.2 Mounting system accessories on the front arm axis

The front arm axis has the space to mount system acces-
sories. (See the figures below.)

Depth: 16

Depth: 12

Viewed from A

(Unit: mm)
Note
When a cable hanger or bracket is mounted, be sure
they don’t interfere with the arm.

32 OM1010105E04
 Technical data

5.3.3 Limitation of the load on the front arm axis

• Standard arm (TA-1600) and Long arm (TA-1800)
The maximum weight (W2) of the system accesso-
ries installed on the front arm axis must be within the
range shown in the graph below including the load on
the wrist axis (W1).

(1)

(1): Distance from FA rotation center (L)

(2) (2): FA rotation center

OM1010105E04 33
 Technical data

• Long arm and 6 kg payload type (TA-1900)

The maximum weight (W2) of the system accesso-
ries installed on the front arm axis must be within the .
range shown in the graph below including the maxi-
mum payload on the wrist axis (W1).

(1)

(1): Distance from FA rotation center(L)

(2) (2): FA rotation center

34 OM1010105E04
 Technical data

5.4 Collision detection

The welding robots “TAWERS” are equipped with Note
highly-sensitive collision detection function. These functions cannot prevent the damage com-
The function stops the robot instantaneously by our pletely.
new collision detection method based on kinematics.
At the same time, the robot becomes flexible. (flex
mode) Note
In these ways, impact and property damage by a col- The following can result in false collision detection:
lision can be minimized. • Incorrectly set load parameters
• Operation without warming up time at low tempera-
Refer to the operating instructions [Operation] for
ture
details.

5.5 Mounting plane of protective fixture

To use the robot for handling operation, mount a pro-
tective fixture (mechanical fuse) instead of shock- Dimensions of the wrist flange
type torch holder for welding operation.This prevents
damage to the robot or the system accessories when
View from A
they interfere with each other by wrong operation.

The following figures show dimensions of the robot 45° ± 0.1°

wrist flange. Use 4-M5 and 4-M6 screws to mount 22.5° ± 0.1°
the protective fixture.
φ4H7
Depth 10

PCD 50 ± 0.2
A 4-M5
Depth 8

4-M6
Depth 12
PCD 26 ± 0.2

φ40H7 φ60

(Unit: mm)

OM1010105E04 35
 Technical data

5.6 Setting welding torch

(1) Set a torch holder and a welding torch to the .
manipulator. Torch positioning stand Bolt M4x12
(2) Attach the provided centering gauge to the torch
Bottom cover
holder.
A
(3) Loosen the bolts A and B, and then adjust the
torch positioning stand so that the wire end is B
positioned at the center hole of the centering Bolt M4x8
gauge (tool center point).
(4) Tighten the bolts A and B tightly. Centering gauge

*Also read the operating instructions of torch holder. End of the centering gauge

Tool center
point
Note
Make sure to position the torch precisely for welding
operation. Failure to do so may cause a positioning
error as trajectory of the torch tip may be out of round Center hole
when the wrist of the torch rotates.

5.7 Tool center point

The arc point at the top of the torch shifts depending Even if the work piece is located within the robot
on the torch position to weld the work piece of differ- work envelope, it can be inaccessible by the arc point
ent locations and figures. Decide the location of the depending on the torch position.
work piece considering the torch position.

Arc point
Point P Point P

Point O

Point O (Unit: mm)

Note: PointsArc
P and
point O are shown on “Work envelope diagram (2).”

Work
Working envelope
envelope of point P diagram (1)
Working envelope of point O

36 OM1010105E04
 Technical data

5.8 Tool offset

This robot moves the torch according to registered
teaching points: The torch tip moves linear or circular
60
by connecting the teaching points at a constant L3
speed.

155 L1
The standard offset values are registered as shown
in the following table. To check the actual offset val- L1
ues, refer to the operating instructions of the safety
holder. For how to use the registered offset values,
refer to the operating instructions of the controller.
L2
To measure the dimensions, see the figure on the (Unit: mm)
right and input them into the controller. View from the bottom.
TW
(Clockwise direction is positive.)
Registered values
Long torch Short Setting range
(Preset) torch
L1 545 505 0 to 999.99
L2 0 0 -999.99 to 999.99
L3 369.7 350 0.01 to 999.99
L4 0 0 -999.99 to 999.99
TW 0° 0° -400° to 400°

L4

5.9 Set-up
After completion of installation and connection of the
manipulator, set initial conditions (including tool off-
set) on the controller.
See the operating instructions of the controller for
detailed set-up instructions.

(Unit: mm)

Work envelope diagram (2)

OM1010105E04 37
 Technical data

5.10 Work envelope

5.10.1 Standard arm type (TA-1600)

60

R460 R1268
R400
R1228

R420
R360

R1598

Work envelope R1538

of point P
(Area:7.50 ㎡ )

Work envelope of point O

(Area: 6.73 ㎡ ) 170°

(Unit: mm)

Note: Points P and O are shown on “Work envelope diagram (2).”

Work envelope diagram (1)

38 OM1010105E04
 Technical data

1598 1288
1538 1228
420 460
360 424
334 400
190 364
28
14

60

Point P

1863 Point O
1803

905
974
683

224

284225 300 373

313

1001
Work envelope
941 of point P
(Area: 5.61 ㎡ )
Work envelope of point O
(Area: 4.84 ㎡ )
295
355
388
186 410
212 470

(Unit: mm)

Work envelope diagram (2)

OM1010105E04 39
 Technical data

5.10.2 Long arm type (TA-1800)

60

R575
R1486
R515
R1426

R532
R472

R1796
Working envelope R1736
of point P
(Area: 9.28 ㎡ )
Working envelope of point O 170°
(Area: 8.39 ㎡ )

(Unit: mm)

Note: Points P and O are shown on “Work envelope diagram (2).”

Work envelope diagram (1)

40 OM1010105E04
 Technical data

1796 1486
1736 1426
532 575
472 515
387
86
68

60

Point P

2061
Point O
2001

1 084
1147

718
100 54 114

384
322 500 571
511

1198
1138
Working envelope
of point P
(Area: 7.24 ㎡ )
Working envelope of point O
(Area: 6.31 ㎡ )
295

355
31
570
39
607 667
355

(Unit: mm)

Work envelope diagram (2)

OM1010105E04 41
 Technical data

5.10.3 Long arm and 6 kg payload type (TA-1900)

60

R659 R1585
R599
R1525

R611

R551

R1895
R1835

Working envelope
of point P
(Area: 10.16 ㎡ )
Working envelope of point O
(Area: 9.21 ㎡ )
170°

42 OM1010105E04
 Technical data

1895 1585
1835 1525
611 659
551 599
485 136
116

60

Point P

2160
2100 Point O

1173
1233

735
156
2

434 96
371
600 670
610

1297
1237
Working envelope
of point P
(Area: 8.08 ㎡ )
Working envelope point O
(Area: 7.07 ㎡ )

48
50
295
355
504
564
660
338 706
766

OM1010105E04 43
 Electrical equipment and wiring parts

6.Electrical equipment and wiring parts

6.1 Location of the limit switches
The limit switches to detect over-travel are pre-
mounted or can be mounted as the following table
shows.

Types RT-axis UA-axis FA-axis

T/Y type Pre-mounted Sold separately Sold separately
E/U/R type Pre-mounted Pre-mounted Pre-mounted

FA-axis limit switch

UA-axis limit switch

RT-axis limit switch

44 OM1010105E04
 Electrical equipment and wiring parts

6.2 Adjusting the limit switches

To limit the working range of an axis, adjust the limit
switches as the following procedure.

At the same time, contact Panasonic authorized ser-

vice personnel and adjust the parameters of the soft-
limit.

6.2.1 Adjusting the limit switch of RT-axis

(1) Remove one of the pre-installed limit dogs.
(2) Install the provided RT stopper to an appropriate Limit dog RT(pre-installed)
place and install the removed limit dog to it.
RT stopper
< Note >
• Readjust the limit dog so that its gliding surface
turns on the limit switch.
Bolt (pre-installed)
• Also see section "3.6 Adjustment".

Gliding surface
Limit dog RT
Motion direction

Limit switch

OM1010105E04 45
 Electrical equipment and wiring parts
6.2.2 Adjusting the limit switches of UA and FA axes
UA and FA axes have holes equally spaced (30
degrees intervals) to mount the limit dogs. (See the
UA axis: 10 holes
figures on the right.)
Change the position of the limit dogs to limit the Limit dogs (Pre-mounted position)
working range of each axis.

FA axis: 11 holes

Limit dogs
(Pre-mounted position)

46 OM1010105E04
 Electrical equipment and wiring parts

6.3 Connecting cables and hoses

Signal cables and air and gas hoses are incorpo-
rated in the manipulator, which makes the welding
system more compact.
User cable connector
(1) Incorporated air and gas hoses:
(a) Max working pressure: 0.5 MPa
(70 PSI, 5 bar)
(b) Hose inner diameter: 5 mm
(2) User cable connector:
The user cable connector CM02-8DR5P(D3) is
attached to the wire feeder:
(a) Corresponding female connector:
CM02A-8DP5S(02)(D4) or equivalent
(b) Recommended manufacturer: DDK Ltd. 1 Gas outlet connector
2
. 4
Pin No. Signal Current/Voltage
1 OPT1+
3 5
2 OPT1-
24 VDC, 1 A or less
3 OPT2+
4 OPT2- Air inlet connector Gas inlet connector
5 OPT3 100 VAC, 3 A or less

(3) Gas outlet connector:

The gas outlet connector KQ2LE06-00 is attached
to the wire feeder.
(a) Connectable hose diameter: 6 mm
(b) Manufacturer: NIHON PISCO
(4) Gas inlet connector:
The gas inlet connector PMF8-02 is attached to the
manipulator.
(a) Connectable hose diameter: Rc1/4 (PT1/4)
(b) Manufacturer: NIHON PISCO
For GV2+ and GV2-
(5) Air inlet connector (unconnected):
(Behind the cables)
The air inlet connector PMF8-02 is attached to the
manipulator. Air outlet connector
(a) Connectable hose diameter: Rc1/4 (PT1/4) (Unconnected)
(b) Manufacturer: NIHON PISCO
Gas outlet connector
(6) RW body side gas outlet connector (unconnected):
(Pre-connected)
The RW body side gas connector PM8 is attached
to the manipulator.
(a) Connectable hose diameter: Converted from
Feeder cable
8 mm to 6 mm
(b) Manufacturer: NIHON PISCO
(7) RW body side air outlet connector (unconnected)
The RW body side air outlet connector PM8 is Note
,,

attached to the manipulator. To use air valve, connect GV2+ and GV2- connectors
(a) Connectable hose diameter: 8 mm to the place shown on the figure.
(b) Manufacturer: NIHON PISCO

OM1010105E04 47
 Electrical equipment and wiring parts

6.4 Connecting power cable

Connect the power cable to the terminal as fol- Figure 5-1
lows:
(a) Pass the power cable through the rubber
cover AWK41018.
(b) Connect the power cable to the terminal with
the provided M8 bolt.
( Recommended tightening torque:
10.1 N•m to 13.4 N•m.)
(c) Insulate the terminal with the robber cover.
(d) Secure the rubber cover to the power cable
with a nylon tie or equivalent.
Note Power cable terminal
•WGH Ⅲ type doesn’t have the power cable termi-
nal.
•The maximum current applicable to the terminal
Rubber cover
is 350 A.

Nylon tie or equivalent

Power cable

48 OM1010105E04
 Electrical equipment and wiring parts

6.5 Internal wiring

Figure 5-2 (1/2)

TW harness Lamp harness (see note)

TWBW harness

BK branch harness

RS relay harness

Rt relay harness

BK relay harness U
BK relay harness R

When harnesses are replaced, apply grease to new ones as the table below shows.
No. Application area Application quantity Grease name
(1) RT-axis rotation part 3 pushes SUMIGREASE SPRAY 259664
(2) UA-axis rotation part Pre-applied
(3) FA-axis rotation part Pre-applied
(4) RW-axis rotation part 2 pushes SUMIGREASE SPRAY 259664
(5) BW-axis rotation part 1g Alvania S2
- Internal power cable 20 g Alvania S2
(Note - For T and Y types, a lamp to indicate servo on is sold separately.
- See section "8. Repair parts lists" for the location of the internal power cable.

OM1010105E04 49
 Electrical equipment and wiring parts

Molex connector
BK relay harness R

BK relay harness U
RS relay harness
(Note2)

*1
*2
(Note5) *3
(Note8) *4
Option 1 *5
(Note7)
*6
Canon plug
*7
(Note3)

*8

Molex connector

*9
*10
*11

*12
*13
RT relay harness
*14

50 OM1010105E04
 Electrical equipment and wiring parts

Figure 5-2 (2/2)

RS : Resolver
M : Motor power
BK : Motor brake power
OT : Over travel
SH : Safety holder
LMP : Lamp power
GV1 : Gas valve power
GV2 : Air valve power
OPT : Option
BAT : Lithium battery

*1
*2
*3
*4 OPT harness
*5
*6 (Note9)
Option 2
*7
(Note3)

*8

(Note4)

BK branch harness

*9
*10
*11

*12
*13

*14

(Note10) TW-BW harness (Note6) TW harness

Note
Note2: Standard spec. (T, Y and E specs) uses ZUEP5759,
however, a PCB with brake release;ZUEP5760, is available as optional unit.
Note3: For T, Y and E specs, UA and FA limit switch is available as optional unit.
Note4: For T, Y and E specs, Servo-ON indication lamp is available as optional unit.
Note5: Connect to the ground terminal (at RT base).
Note6: Connect to the ground terminal (at BW body).
Note7: Canon plug “C”: User connector. (Not applicable to TAWERS.)
Note8: “Option 1” changes wiring when the canon plug “C” is used.
Note9: “Option 2” changes signals when the canon plug “C” is used.
Note10: Connect to the ground terminal (RW body).

OM1010105E04 51
 Electrical equipment and wiring parts

6.6 Manual brake release switch

T/Y Sold separately
E/U/R Standard equipment

Pay special attention when releasing brake for basic axes. Gravity drop
CAUTION at high speed may cause serious injury or damage to the equipment.

The manual brake release switch is installed on RT-

body. (See the right figure.) Take the following steps Brake release switch
to release brake of each axis manually:
RELEASE-SW
(1) Make sure to press the emergency stop switch.
(2) Turn ON the breaker of the controller. RT・WRIST
(3) Turn the axis select switch to the axis name and select switch
then press the RELEASE-SW (release switch)
on the side of the UA arm body together to UA・FA
release the brake. select switch
Note
• RT, UA and FA axes brakes can be released individually.
• RW, BW and TW-axes brakes are released all together.

6.7 Servo-ON indicator lamp

T/Y type Sold separately

E/U/R type Pre-mounted

The servo-ON indicator lamp lights up when servo

motors are powered on. Be aware that the manipula-
tor has the potential to move when this lamp is
lighted.

Servo-ON indicator lamp

52 OM1010105E04
 Maintenance and inspection

7.Maintenance and inspection

Perform maintenance and inspection of the robot to Maintenance and inspection intervals
ensure performance and to prevent breakdown. 1 Daily inspections

Maintenance and inspection intervals are different
depending on maintenance and inspection items
(see the table on the right).
Apply either total operating hours (when the control-
ler power is on) or period after the first use, which-
ever comes first.
Have our overall inspection including overhaul after
having every 2 000-hour inspection.
If you enter into a periodical inspection contract with
us, our periodical inspections will cover 2 000-hour
(or annual) to 10 000-hour (or 5 years) inspection.
2 Every 500 hours or 3 months
3 Every 2 000 hours or 1 year
4 Every 4 000 hours or 2 years
5 Every 6 000 hours or 3 years
6 Every 8 000 hours or 4 years
7 Every 10 000 hours or 5 years
Note
The intervals above are for welding operations.

7.1 Daily check

♦Inspections before turning on the power

Parts Item Service Remarks
Ground cable Looseness Re-tightening.
Cables Breaking or damage of wire Replacement
Do not clean the robot with com-
Attachment of spatter or Removal of spatter or pressed air or cleaning water. Spat-
dust dust ters, dust, or water may get inside the
Manipulator robot and damage it.
Consult our service section if causes
Looseness Re-tightening
are not clear.
Safety fence Damage Repair
Working area Tidiness

♦Inspections after turning on the power

Parts Item
Emergency Turn off the servo power
stop switch immediately.
When the home return is com-
Origin
pleted, the origin matchmarks
matchmarks
coincide with each other.
Each axis makes steady and
smooth motions (no abnormal
Manipulator vibration, noise or looseness)
in manual and operation
mode.
Cooling air inlet fan of the con-
Fan troller rotates.
Attachment of dust on the fan.
Center tube and stainless
Wire feeder
tube for dust and dirt.
Service Remarks
Repair
Do not use the robot unless the switch
Consult us if causes
is repaired.
are not clear.
To approach the robot to check the
Consult us if they do
matchmarks, press the emergency stop
not match.
switch and turn off the servo power.
Consult us if causes Do not use the robot unless the manipu-
are not clear. lator is repaired.
Turn off the power to the controller
Clean the fan.
before cleaning the fan.
Remove dust or dirt.

OM1010105E04 53
 Maintenance and inspection

7.2 Periodical inspection

Interval
3 mth 1 yr 2 yr 3 yr 4 yr 5 yr Item Method /Tool Inspection and service
(500 h) (2 000 h) (400 h) (6 000 h) (8 000 h) (10 000 h)
Check for tightness and
9 Robot fixing bolts Wrench
re-tighten if necessary.
Driver Check for tightness and
9 Screws at covers
Wrench re-tighten if necessary.
Check for tightness and
9 Connecting cable connectors Feeling
re-tighten if necessary.
Check for wear or defor-
Feed roller of the wire feeder, Feeling, mation of the groove and
9 feed gear and drive gear Visual gear, and replace it if it is
significant.
Check for tightness and
9 Motor mount bolts Wrench
re-tighten if necessary.
Torque wrench
Check tightening torque.
9 Rotation / drive parts Feeling,
Check for looseness.
Visual
Torque wrench Check tightening torque.
9 Reduction gears
Visual Check visual appearance
Torque wrench Check tightening torque.
9 Wire feeder fixing parts
Visual Check visual appearance
Conductivity test
Power cable Tester,
9 Internal power cable Visual
Check visual appearance
Apply grease *
Conductivity test
Inner wiring and Tester,
9 connectors of the manipulator Visual
Check visual appearance
Apply grease *
Worm gear, worm wheel inside
Apply grease
9 and spiral bevel gear of wire Grease
(About 5 g)
feeder
9 Timing belts of the wire feeder Feeling Adjust
9 Batteries (Manipulator) Exchange Exchange with new one
Exchange with new one
9 Timing belts of the wire feeder Exchange
Adjust tension \
9 Reduction gears Grease Apply grease
Check tensile force and
9 Timing belts of the manipulator Tension meter
adjust if necessary
Power cable Exchange with new one
9 Exchange
Internal power cable Apply grease
Exchange with new one
9 Inner wiring of the manipulator Exchange
Apply grease
Exchange with new one
9 Timing belts of the manipulator Exchange
Adjust tensile force
Limit switch
Brake release switch
Exchange with new one
Inner printed circuit board Tester,
9
Rubber cover Visual
Adjust
Nylon clamp
Rubber sheet

• Consult our service section for details.

• If you enter into a periodical inspection contract with us, our periodical inspections will cover 2 000-hour (or
yearly) inspection to 10 000-hour (or 5 years) inspection.
• Replacement parts will be charged.

54 OM1010105E04
 Maintenance and inspection

• Refer to the operating instruction of controller for check items for the controller.
• Select the grease as follows:
- TW axis (Harmonic drive reduction gear): Harmonic grease SK-2
- BW, RW axes (Harmonic drive reduction gear): Harmonic grease SK-1A
- FA, UA, RT axes (RV reduction gear): VIGOGREASE RE0
- Worm gear and worm wheel of wire feeder: Alvania S2
*Do not disconnect the resolver. Just check the appearance of it.

Note
• Before using the grease, be sure to read its instruction manual for appropriate use.
• Be sure to wear eye protector and thick gloves when refilling the grease.
• If in eyes or mouth, rinse well with water immediately and submit to medical treatment.

7.3 Backup battery replacement

The manipulator is provided with batteries to retain Note
resolver’s backup data.
• When the battery is weakened, the position data of the
The following cases require battery replacement. Contact
resolver can be lost and on-site origin adjustment
Panasonic authorized service personnels.
becomes necessary again. Replace the battery before
(1) When the following error message (battery error mes-
this happens.
sage) appears.
• While the battery error message is displayed, the robot
E8000 Encoder battery is consumed: cannot be turned on. Clear the error message to start the
The battery in the manipulator. robot.

(2) Before storing the manipulator for 2 years or more

without electric connection.

OM1010105E04 55
 Maintenance and inspection

7.4 Setting adjustment pins

(1) To adjust the origin, follow the instructions displayed
on the teaching pendant and set the adjustment pins. Adjustment pin for RT, UA and FA axes

Note Line mark

4
• For “On-site origin adjustment”, refer to the operating
instructions [Operation].
• In normal operation, make sure that the adjustment
pins are completely retracted. If the adjustment pins
Adjustment pin for RW and BW axes
crash occurs during operation, on-site origin adjust-
ment will be inaccurate. Line mark
2.5
(2) Pull out the adjustment pins to the line mark to com-
plete the adjustment pins setting.
(At the initial adjustment, remove the seals stuck on
top of the adjustment pins.)
Continue “On-site origin adjustment” referring to the Adjusting pin for UA axis
operating instructions [Operation].
Note
Make sure that setting surfaces are free from for-
eign substances.
Setting surface

(3) Location of adjustment pins and setting surfaces

RW axis

Adjustment pin

Setting face

FA axis
BW axis

Setting face
Setting face Adjustment pin
Adjustment pin

UA axis

RT axis

Adjustment pin
Adjustment pin
Setting face
Setting face

56 OM1010105E04
 Maintenance and inspection

7.5 Checking bolts tightening torque for wire feeder

Check the bolts tightening torque for wire feeder
annually or every 2 000 operating hours. See the fol-
lowing figures for proper tightening torque for each
bolt.
Note
Tighten all the bolts properly as the figures below.
Failure to do so may cause the wire feeder to fall
down or the welding cable connection part to gener-
ate excess heat or fire.

1)Standard feeders:
M8x15 (1 pc.)
23 ±0.2 N・m
(The same to the opposite side.)

M5x55 (3 pcs.)
5.5 ±0.05 N・m

M8x35 (2 pcs.)
37 ±0.4 N・m

M6x15 (5 pcs.)
7.3 ±0.1 N・m
M5x12 (4 pcs.) M8x35 (2 pcs.)
3 ±0.03 N・m 37 ±0.4 N・m

2)High-powered and high-powered (for 450 A welder) feeders:

M8x15 (1 pc.)
23 ±0.2 N・m
(The same to the opposite side.)
M6x15 (2 pcs.) M6x15 (2 pcs.) M5x15 (2 pcs.)
5.5 ±05 N・m 5.5 ±0.05 N・m 3 ±0.03 N・m

M6x15 (4 pcs.) M5x15 (4 pcs.) M6x15 (4 pcs.)

5.5 ±0.05 N・m 3 ±0.03 N・m 5.5 ±0.05 N・m

OM1010105E04 57
 Maintenance and inspection

7.6 Maintenance of wire feeder

CAUTION Turn off all power before starting maintenance.

Note
• Open the feeder cover to conduct periodic check of wire feeder.
• Be sure to conduct periodic check at intervals specified below.

7.6.1 Maintenance and periodical check

1)Stainless tube and center tube
Check the following items weekly.
Check items
Check if the entrance of the stainless tube and the
center tube, and around the feed rollers are clean.
Check if the stainless tube and the center tube are
compatible with the wire diameter or vice versa.
Check if the holes of the stainless tube and the cen-
ter tube are aligned with the center of the feed roller
groove.
Notes
• Remove dust.
• Clean once a week.
Using wrong tubes or wire creates more wire shav-
ings, and causes clogging of the liner and unstable
arc.
Align them precisely. Improper alignment causes
unstable arc and creates more wire shavings.

2)Feed roller
Check the following items every 2 or 3 months.
Check items
Check if the feed rollers are compatible with the wire
diameter or vice versa.
Check the condition of the feed roller groove.
Notes
Using wrong rollers or wire creates more wire shav-
ings, and causes clogging of the liner and unstable
arc.
If worn or cracked, replace it with a new one.

3)Worm gears and worm wheels (standard), spiral bevel gear (high-powered)
Apply 5 g of Albania S2 grease to the worm gears
and the worm wheels through the “GREASE INLET”
every year.

58 OM1010105E04
 Maintenance and inspection

7.6.2 Change of feed rollers, stainless tube and center tube

Change feed rollers, stainless tube and center tube .

Stainless
depending on the wire diameter. (See the table on Wire size Feed roller Center tube
tube
the right.)
Follow the following steps: MDR00051
0.9 / 1.2
(1) Pull the pressure nuts (1) toward to unlock the (APU01078)
MGT00004 MGW00012
pressure arms (2), and then lift the pressure MDR00053
1.0 / 1.2
arms. (APU01091)
1.2 / 1.4 MDR00055 MIG00011 MGW00010
(2) Unscrew the setscrews (3) of the feed rollers.
(3) Remove the feed rollers (4).
(4) Pull out the stainless tube (5) rightward, and
then insert appropriate one. ②
②
(5) Attach the feed rollers to the shafts so that the ① ⑥
imprints of the wire diameter are on the front
side.
⑤ ⑧
(6) Unscrew the sems screws (6) and remove the
wire guide metal (7).
①
(7) Loosen the sems screw (8), pull out the center ③ ③
tube (9) from wire guide metal (7) and insert
appropriate one. ④
⑨ ④ ⑦

OM1010105E04 59
 Repair parts lists

8.Repair parts lists

See the recommended repair parts lists and have
parts in stock if needed.

8.1 Robot manipulators

43

20

3 29 35

36

21

3 30

44

< View from the front >

60 OM1010105E04
 Repair parts lists

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts
Part number Stock Quantity
No. Description Part number Class Remarks
to order needed used
Harmonic gears of TW
1 Grease SK-2 SK2-05K A 1 -
(2 kg can)
Harmonic gears of BW,
2 Grease SK-1A SK1A-05K A 1 -
and RW (2 kg can)
RV reduction gears of FA,
3 VIGOGREASE RE0 V1G0GRE0-2K YAA322 A 1 - UA and RT axes
(2 kg can)
4 Lithium battery ER6VCT ER6VCT A 6 6 For backup(*1))

5 RT harness AWC12828 AWC12828 A 1 1 (*2)

AWC32814 AWC32814 A 1 1 TA-1600(*2)

6 TW-BW harness AWC32815 AWC32815 A 1 1 TA-1800(*2)

AWC32816 AWC32816 A 1 1 TA-1900(*2)

7 TW harness AWC42334 AWC42334 A 1 1 (*2)

8 RS relay harness AWC42292 AWC42292 A 1 1 (*2)

9 BK relay harness U AWC42293 AWC42293 A 1 1 (*2)

10 BK relay harness R AWC42315 AWC42315 A 1 1 (*2)

11 OPT harness AWC32766 AWC32766 A 1 1 (*2)

12 BK branch harness AWC32768 AWC32768 A 1 1 (*2)
13 Lamp harness AWC32767 AWC32767 A (1) (1) Sold separately
14 Lamp DM22K0LE03Y YABD55 A (1) (2) Sold separately
15 Timing belt 100S3M432 YAA222 B 1 1 For BW axis
16 Limit switch AEB31006 AEB31006 B 1 1 For RT axis
For UA and FA,
17 Limit switch AEB31006 AEB31006 B (1) (2)
Sold separately
18 Pinion gearH20 ADG41081 ADG41081 B 1 1 For RW axis
19 Input gearH20 ADG41082 ADG41082 B 1 1 For RW axis
20 Input gearR25 ADG32012 ADG32012 B 1 1 For FA axis
21 Input gearR50 ADG32011 ADG32011 B 1 1 For UA axis
22 Pinion geaR60 ADG41083 ADG41083 B 1 1 For RT axis
23 Input gearR60 ADG41084 ADG41084 B 1 1 For RT axis
24 Worm gear A 1 1 Wire feeder(*3)

25 Worm gear wheel A 1 1 Wire feeder(*3)

26 Harmonic drive gear SF1750RR81T YAA186 B 1 1 For TW axis

27 Harmonic drive gear SG2080RR81B YAA185 B 1 1 For BW axis
28 Harmonic drive gear HG2080RR81R YAA184 B 1 1 For RW axis
29 RV reduction gear 28E045-1 YAA187 C 1 1 For FA axis
30 RV reduction gear 38E023-1 YAA188 C 1 1 For UA axis
31 RV reduction gear 38L001-1 YAA189 C 1 1 For RT axis

OM1010105E04 61
 Repair parts lists

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used
32 Servo motor unit TS4603N8030 YAA241 C 1 1 For TW axis

33 Servo motor unit TS4607N8337 YAA296 C 1 1 For BW axis

34 Servo motor unit TS4609N8337 YAA297 C 1 1 For RW axis

35 Servo motor unit TS4614N8337 YAA298 C 1 1 For FA axis

36 Servo motor unit TS4833N9031 YAAD73 C 1 1 For UA axis

37 Servo motor unit TS4832N9030 YAA151 C 1 1 For RT axis

38 Servo motor unit C 1 1 Wire feeder(*3)

39 Brake card ZUEP5759 ZUEP5759 C 1 1

40 Resolver card ZUEP5764 □ B1 ZUEP5764 □ B1 C 1 1 For TW, BW and RW

41 Resolver card ZUEP5764 □ ZUEP5764 □ C 1 1 For FA, UA and RT axes

42 Coupling A 1 1 Wire feeder *3)

43 Power cable ACC01023 ACC01023 A 1 1 (*5)

43-1 Rubber sheet AFQ40005 AFQ40005 A 2 2 Included in No.43 (*5)

44 Internal power cable AWC32901 AWC32901 A 1 1 (*5)

Safety part
- Fuse SS2-3AN1 YZAD276 C 1 1
(In RW body）
For harness rotary parts of
SUMIGREASE
- Grease YAA311 A 1 - RT and RW axes (*2)
SPRAY 259664
(* 330-ml canned splay)
Harness rotary parts of
YWA45
- Grease Albania S2 A 1 - BW axis(*2)
(400 g)
(0.4 kg tube)
- Nylon clamp NK12N YZA77 A 2 2 For fixing power cable
- Eye bolt XVN12FJ XVN12 - 2 2 (*4)
Note: (*1): Average lifetime is approximately 2 years.
(*2)
: See “Internal wiring” section.
(*3): Included in the wire feeder motor unit. For details, see “8.3.1Motor unit .“
(*4)
: If you lose or break the eye bolt, purchase Panasonic genuine one for safe transportation.
(*5)
: WGH Ⅲ type doesn’t have these parts inside.

62 OM1010105E04
 Repair parts lists

8.2 Wire feeder (Standard)

⑥ ③ ⑤ ④ ⑫

⑪
⑭
②
⑩ ⑨

Note: The above figure is for standard floor system.

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock

No. Description Part number Class Quantity used Remarks
to order needed

1 Motor unit ADU01506 ADU01506 - - 1

2 UF base ADB12002 ADB12002 - - 1

3 MDA00004 MDA00004 A 1 1
Pressure arm
4 MDA00005 MDA00005 A 1 1

5 pressure roller ass’y MDR00060 MDR00060 A 2 2

6 Pressure adjust MDX00008 MDX00008 A 2 2

7 CC fitting MFC00011 MFC00011 A 1 1

9 Feed roller MDR00051 MDR00051 A 2 2

10 Feed roller gear MDG00010 MDG00010 A 2 2

11 Stainless tube MGT00004 MGT00004 A 1 1

12 Center tube MGW00012 MGW00012 A 1 1

13 Flexible conduit metal MGW00016 MGW00016 A 1 1

14 Flat head screw XSS35+16V YZA95

A 4 4

OM1010105E04 63
 Repair parts lists

8.2.1 Motor unit

⑤ ④ ③ ② ①

Note: The above figure is for standard floor system.

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used

1 Motor uni TS4602N3030 YAA242 C 1 (1) Included in motor unit

For standard type

ASJHZ17-8-8 YAW129 A 1 (1) Included in motor unit
2 Coupling
For CE type
MCOG20-8-10 YAW104 A 1 (1) Included in motor unit

3 Worm gear ADW41068 ADW41068 A 1 (1) Included in motor unit

4 Worm gear wheel ADW41064 ADW41064 A 1 (1) Included in motor unit

5 Drive gear ADR41006 ADR41006 A 1 (1) Included in motor unit.

64 OM1010105E04
 Repair parts lists

8.3 Wire feeder (Standard)

⑥ ③ ⑤ ④ ⑫

⑦
⑪
⑭
②
⑩ ⑨

Note: The above figure is for standard floor system.

The repair parts are classified as follows:
A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used

1 Motor unit ADU01506 ADU01506 - - 1

2 UF base ADB12002 ADB12002 - - 1

3 MDA00004 MDA00004 A 1 1
Pressure arm
4 MDA00005 MDA00005 A 1 1

5 pressure roller ass’y MDR00060 MDR00060 A 2 2

6 Pressure adjust MDX00008 MDX00008 A 2 2

7 CC fitting MFC00011 MFC00011 A 1 1

9 Feed roller MDR00051 MDR00051 A 2 2

10 Feed roller gear MDG00010 MDG00010 A 2 2

11 Stainless tube MGT00004 MGT00004 A 1 1

12 Center tube MGW00012 MGW00012 A 1 1

13 Flexible conduit metal MGW00016 MGW00016 A 1 1

14 Flat head screw XSS35+16V YZA95 A 4 4

OM1010105E04 65
 Repair parts lists

8.3.1 Motor unit

⑤ ④ ③ ② ①

Note: The above figure is for standard floor system.

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used

1 Motor unit TS4602N3030 YAA242 C 1 1

ASJHZ17-8-8 YAW129 A 1 1 For other than CE type

2 Coupling
MCOG20-8-10 YAW104 A 1 1 For CE type

3 Worm gear ADW41068 ADW41068 A 1 1

4 Worm gear wheel ADW41064 ADW41064 A 1 1

5 Drive gear ADR41006 ADR41006 A 1 1

66 OM1010105E04
 Repair parts lists

8.4 Wire feeder (High power / For 450 A welding power source)

③ ⑤ ④ ⑫
⑥

① ⑪

⑬ ⑦

②
⑭

⑩ ⑨

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used
1 Motor unit ADU01577 ADU01577 － － 1
2 UF base ADB12002 ADB12002 － － 1
3 MDA00004 MDA00004 A 1 1
Pressure arm
4 MDA00005 MDA00005 A 1 1
5 pressure roller ass’y MDR00060 MDR00060 A 2 2
6 Pressure adjust MDX00008 MDX00008 A 2 2
7 CC fitting MFC00011 MFC00011 A 1 1

For 450A
9 Feed roller MDR00055 MDR00055 A 2 2 power source
(high power)
10 Feed roller gear MDG00010 MDG00010 A 2 2

For 450A
11 Stainless tube MGT00011 MGT00011 A 1 1 power source
(high power)
For 450A
12 Center tube MGW00010 MGW00010 A 1 1 power source
(high power)
13 Flexible conduit metal MGW00016 MGW00016 A 1 1

14 Flat head screw XSS35+16V YZA95 A 4 4

- Feeder cover unit AKU01235 AKU01235 - - 1

OM1010105E04 67
 Repair parts lists

8.4.1 Motor unit

①
②

⑥ ⑤ ④ ③

The repair parts are classified as follows:

A: Consumables or frequently replaced parts
B: Frequently moving parts or mechanical elements
C: Important mechanical elements or electric parts

Part number Stock Quantity

No. Description Part number Class Remarks
to order needed used

1 Servo motor TS4606N3337 YAA301 C 1 (1) Included in motor unit

2 Reduction gear VRGF-11B60-MY YAA293 B 1 (1) Included in motor unit

3 Timing belt 060S3M312UG YAA290 B 1 (1) Included in motor unit

4 Spiral miter MMSA2-20L YAA292 B 1 (1) Included in motor unit

5 Spiral miter MMSA2-20R YAA291 B 1 (1) Included in motor unit

6 Drive gear ADR41006 ADR41006 A 1 (1) Included in motor unit

68 OM1010105E04
 Appendix

9.Appendix
9.1 Location of the labels

Caution label
MNT00008

OM1010105E04 69
 Appendix

9.2 Details of the labels

YA-1 □ AR8 □□□□

YA-1 □ MR8 □□□
6
20□□

< Type label >

< ANT40157 >

< ANT40113 >

< ANT41216 >

< ANT40159 >

<BNTL0015 >
< MNT00008 >

< CE mark - ANH42332 > < ANT41533 >

< UL mark - ANH35002 >

70 OM1010105E04
 MEMO

OM1010105E04 71
パナソニック溶接システム株式会社
〒 561-0854 大阪府豊中市稲津町 3 丁目 1 番 1 号
TEL: (06)-6866-8556（代表）
FAX: (06)-6862-1441
ホームページ : http://panasonic.co.jp/pws/
Panasonic Welding Systems Co., Ltd.
1-1, 3-chome, Inazu-cho, Toyonaka, Osaka 561-0854, Japan
TEL: 81-6-6866-8505
FAX: 81-6-6866-0709
URL:http://panasonic.net/pws/

© Panasonic Welding Systems Co., Ltd. 2011 Printed in Japan.

OM1010105E04